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Technical Paper

High rigidity and light weight bumper material development in India

2019-11-21
2019-28-2553
Vehicle weight reduction becomes important at the view point of fuel efficiency improvement and CO2 reduction in India also as well as developed countries. With this background, High tensile and Super high tensile steel application has become increasing. Similary, weight reduction of big plastic parts like bumper face is one of the most important items, so Honda has developed Thin-wall and light weight bumper face. In the development of light weight bumper, rigidity, impact strength and flowability which are main requirement are cotradictory property. It is necessary to develop new material to achieve this technical concern. Moreover, we verified part shape and thickness optimization to achieve part requirement. Established high property material and part manufacturing technology were applied for current CITY firstly, and it has been expanded to other models sequentially to contribute weight reduction for Honda vehicles.
Technical Paper

Self-Sensing, Lightweight and High Modulus Carbon Nanotube Composites for Improved Efficiency and Safety of Electric Vehicles

2019-11-21
2019-28-2532
Carbon Composites (CFRP) have been touted to be an essential component of future automobiles due to their mechanical properties and lightweight. CFRP has been adopted successfully for secondary and primary structures in Aerospace industry. In Automobiles, they are incorporated in models like the BMW i-series. CFRP suffers from 2 major problems. Delamination of Composites leads to catastrophic and rapid failure which could be dangerous in passenger vehicles. Delamination occurs whenever there is a shock on the composite. Secondly, Composites need regular expensive maintenance to ensure that the material is intact and will not compromise passenger safety. Carbon Nanotubes in composites have shown a substantial increase in delamination resistance. A 0.1wt% addition of HiPCO® Single-walled Carbon Nanotube provides both self-sensing and improved fracture resistance.
Technical Paper

C123 Methodology for concept design of the Chassis Frame

2019-11-21
2019-28-2534
Objective This paper explores the usage of Altair simulation driven concept process, C123 for developing the chassis frame of the SUV along with Multidisciplinary optimisation tool. C123 process is useful for strategic & systematic usage of optimisation to generate design alternatives, trade-off information, best balanced designs, design sensitivities, to actively support the concept development process on daily basis. Methodology C123 is used for developing initial concept design of the chassis frame of the SUV. C123 process is independent of vehicle architectures, manufacture process (e.g. extrusions, sheet metal) & material selection (e.g. metals, composites, mixed etc.) and platform sharing strategy. C1 process is used for identification of optimum Structural Layout, C2 is for rapid optimum Sizing of idealized Sections, C3 is used for detailed optimum Sizing of Manufacturable Sections. Automatic process is used for handling pre and post processing process very efficiently.
Technical Paper

High Durable PU Metallic Monocoat system for tractor sheet metal application.

2019-11-21
2019-28-2541
In sheet metal painting for various applications like Tractor, Automobile, most attractive coating is metallic paints and it is widely applied using 3 coats 2 bake or 3 coat 1 bake technology. Both options, results in high energy consumption, higher production throughput time & lower productivity in manufacturing process. During various brainstorming & sustainable initiatives, paint application process was identified for alternative thinking to reduce burden on environment & save energy. Various other industry benchmarking & field performance requirement studies helped us identify the critical to quality parameters. We worked jointly with supplier to develop mono-coat system without compromising the performance & aesthetical properties. This results in achieving better productivity, elimination of two paint layers, substantial reduction in volatile organic content, elimination of one baking cycle and energy saving.
Technical Paper

Characterization and Durability of Mold-In-Color Engineering Plastics

2019-11-21
2019-28-2542
Plastics are prone to photo oxidative and thermal oxidative degradation under usage conditions due to their chemical nature. From sustainability and cost standpoint, there is an increasing focus on Mold-In-Color (MIC) plastic materials. Simultaneously customer’s expectations on the perceived quality of these MIC parts has been increasing with attractive color and glossy appearance. A study was conducted to analyze the product quality and durability aspects over a prolonged exposure to accelerated weathering condition. Material selected for this study were injection molded specimens of ABS and PC/ABS used in automotive passenger vehicles.
Technical Paper

STATISTICAL ANALYSIS OF LOW CYCLE FATIGUE PROPERTIES IN METALS FOR ROBUST DESIGN

2019-11-21
2019-28-2576
Objective: In ground vehicle industry, strain life approach is commonly used for predicting fatigue life. This approach requires use of fatigue material properties such as fatigue strength coefficient (σf'), fatigue strength exponent (b), fatigue ductility coefficient (εf'), fatigue ductility exponent (c), cyclic strength coefficient (K′) and cyclic strain hardening exponent (n′). These properties are obtained from stable hysteresis loop of constant amplitude strain-controlled uniaxial fatigue tests. Usually fatigue material properties represent 50th percentile experimental data and doesn't account possible material variation in the fatigue life calculation. However, for robust design of vehicle components, variation in material properties need to be taken into account. In this paper, methodology to develop 5th percentile (B5), 10th percentile (B10) and 20th percentile (B20) fatigue material properties are discussed.
Technical Paper

EXPERIMENTAL INVESTIGATION ON THE PERFORMANCE AND EMISSION CHARACTERISTICS OF A DIRECT INJECTION DIESEL ENGINE USING BLENDS OF ETHYL ESTER OF JATROPHA OIL AND ETHANOL

2019-11-21
2019-28-2378
The need of Diesel as fuel has greatly pressurized the now scarcely available natural resources and is likely to become a luxury for the future generations. This paper aims at finding an alternate for diesel that can hopefully reduce the pressure on its existing demand. This paper presents a comparative study on use of different blends of Jatropha Oil (J) and Ethanol (E) as fuel in a diesel engine to observe its performance and emission characteristics. The findings are later compared with corresponding values of neat Diesel as fuel. Since Jatropha oil is more viscous and has polyunsaturated characteristics in its natural form, its ethyl ester was produced by transesterification process and later blended with Ethanol in different proportions like 90% J 10%E, 80J-20E, 70J-30E and 60J-40E.
Technical Paper

Bio diesel-an alternative fuel similar to conventional or ‘fossil’ diesel.

2019-11-21
2019-28-2385
Currently Automotive industry is looking for sustainable alternate of Conventional fuels. Bio diesel is an alternative fuel similar to conventional or ‘fossil’ diesel. It is produced from vegetable oil, animal fats, tallow and waste cooking oil. Bio diesel is one of the most promising fuel which can not only replace the conventional fuels but also environment friendly in terms of Greenhouse gases emission. Bio diesel can be produced from various sources and can be sustainable fuel for automotive vehicles. In this paper, efforts have been taken to convert existing Diesel engine into Bio diesel compliant engine. For making suitable for Biodiesel operation, modification in Engine Fuel system, filter and Sealing were carried out. Further Engine performance and emission testing were done and results were compared with performance and emission of same configuration Diesel engine.
Technical Paper

Utilization of treated waste engine oil -butanol blends as fuel for CI engine operated under an optimal engine parameters

2019-11-21
2019-28-2383
Butanol is an attractive alternative fuel to fuel diesel engine. Waste engine oil is causing land pollution and contamination to groundwater a lot. This experimental study is to investigate the performance of treated waste engine oil and butanol as fuel to diesel engine operated under optimal engine operating parameters. This study was conducted in four stages: Treating the waste engine oil; Preparation of blends and testing the properties; Arriving at an optimal injection timing, nozzle opening pressure, compression ratio, and intake air temperature to suit the possible blend of treated waste engine oil and butanol; Testing the possible blend under optimal operating parameters under various load conditions. The properties test indicated that 35% of butanol can be blended with treated engine oil with respect to the essential properties for fueling diesel engine. To optimize the parameters L16 orthogonal array with the Taguchi method was used.
Technical Paper

Utilisation Treated Waste Engine oil and Diesohol blends as fuel for Compression Ignition Engine – An Experimental Study

2019-11-21
2019-28-2384
Diesel Ethanol (Diesohol) blends are one of the suitable alternative fuel to replace diesel for fueling the compression ignition engines. This experimental study is to utilize optimal fuel blend that contains a higher volume of ethanol in diesel with treated waste engine oil as co-solvent for preventing the phase separation. This study includes three stages: Treating the waste engine oil, preparation of diesel ethanol blends with treated waste engine oil as co-solvent, testing the blends for solubility, properties and performance in a compression ignition engines. Treatment of waste engine oil was conducted in five steps including the acid-clay treatment, in which acetic acid and fuller earth were used as treating materials. Solubility test was conducted for various proportions of diesel-ethanol blends (from 0% to 50% of ethanol by volume) and treated waste engine oil (from 5% to 25%). The stable blends were tested for essential properties as per the ASTM standards.
Technical Paper

Optimization of Bio-diesel fuel filter Size media and configuration for longer service interval .

2019-11-21
2019-28-2391
Bio diesel is one of the most promising fuel which can not only replace the conventional fuels but also environment friendly in terms of Greenhouse gases emission. Adaptation of Bio diesel comes with reduced maintainability and high maintenance cost. Blends of biodiesel and conventional diesel are most commonly used in automotive diesel engines. Biodiesel is most popular choice as an alternate fuel of fossil diesel due to its easy availability, eco-friendly nature and minimum change in existing diesel engine for retro fitment. In this paper efforts have been taken to optimize the life of Fuel filter for bio diesel application. For improving Fuel filter life, modifications carried out in Fuel filter media, size and configuration. Further, Fuel filter tested on Engine test bed and Vehicle to establish the life of filter in real world usage condition. Testing Results were compared with existing diesel fuel filter.
Technical Paper

Optimization of the critical parameters affecting the fuel lid performance

2019-11-21
2019-28-2413
Fuel lid is one of the parts which are mostly operated mechanically by the end user while filling the fuel. Therefore part design should be done in such a manner that it can be operated smoothly without any hassles. The conventional steel fuel filler doors are of two types: Three-piece type fuel filler doors also known as the dog-leg type and two-piece type fuel filler doors also known as the butterfly type. Both types of fuel filler doors have a pin that acts as a rotational hinge axis about which the fuel filler door opens and closes. Depending on the styling and shape of the side body outer, fuel lid type is decided. In the current study, dog-leg type fuel lid is considered. The factors that primarily affect the opening-closing performance are the weight of fuel lid, hinge axis, and the friction at the hinge area. The orientation of the hinge axis is derived from the profile of the side body outer panel. The fuel lid weight and hinge axis are decided in the initial design stage.
Technical Paper

Effect of Eccentric imbalance of various crank train components on Vibrations in single cylinder Diesel Engines

2019-11-21
2019-28-2417
A Vibration analysis is about the art of looking for changes in the vibration pattern and then relating those changes. Vibration generates from Excitation forces due to firing, structural properties like stiffness of the engine and dynamic response. The unbalance masses percentage variation will effect on increasing in Vibration of the diesel engine with respect to Change in Speed. Inherent vibration in engine cause due to combustion is depend upon various crank mechanism, fuel or air flow, gear wheels ,unbalanced turbocharger,etc.. Individual balancing of parts and its combined effect after assembly will totally change the scenario of vibration .Shifting of vibration pattern from Lateral to Vertical plays significant role in this. Changing an eccentric mass direction gives harmonic impact in vibration. Changes in acceleration/displacement pattern with different percentage of balancing.
Technical Paper

Optimization of Compression Ratio for DI Diesel Engines for better fuel Economy

2019-11-21
2019-28-2431
Fuel economy is becoming one of the key parameter as it not only accounts for the profitability of commercial vehicle owner but also has impact on environment. Fuel economy gets affected from several parameters of engine such as Peak firing pressure, reduction in parasitic losses, improved volumetric efficiency, improved thermal efficiency etc. Compression ratio is one of key design criteria which affects most of the above mentioned parameters, which not only improve fuel efficiency but also results in improvement of emission levels. This paper evaluates the optimization of Compression ratio and study its effect on Engine performance. The parameters investigated in this paper include; combustion bowl volume in Piston and Cylinder head gasket thickness as these are major contributing factors affecting clearance volume and in turn the compression ratio of engine. Based on the calculation results, an optimum Compression Ratio for the engine is selected.
Technical Paper

Electric hybrid system Architecture & Functional component selection criteria for application based Off-Highway segment

2019-11-21
2019-28-2495
Hybridization continues to be growing trend in vehicular applications. Current study shows a holistic system approach for the design & integration of the powertrain in Off-Highway tractor applications. It includes study & benchmarking of system architecture of an all-electric and diesel-electric drive systems as per application requirement. Further comprehensive study was done on functional components for an electric powertrain, which includes electric drives, batteries & controllers. Selection & design of these components was studied & component selection approach was developed for typical Off-Highway tractor application. Current study was divided into three parts. 1.Study of different Off-Highway tractor applications & selection of all-electric, series & parallel hybrid architectures as per application requirement.
Technical Paper

Design and Development of Constant speed diesel engine up to 20 bar BMEP with Inline FIS

2019-11-21
2019-28-2549
Design and Development of Constant speed diesel engine up to 20 bar BMEP with Inline FIS Remesan CB, Sanjay Aurora, Vasundhara V Arde, Vishal Kumar, Om Prakash Yadav, Piyush Ranjan Eicher Engines (A unit of TAFE Motors & Tractors Ltd.) Abstract Development trend in diesel engine is to achieve more power from same size of engine. With increase in brake mean effective pressure (BMEP), the peak firing pressure will also increase. The methodology to control the peak firing pressure on higher BMEP is the major challenge. We achieved better SFC with CPCB II emission targets on a constant speed engine. This study involves a systematic approach to optimize combustion parameters with a cost effective and robust inline Fuel Injection System. This paper deals with the strategies applied and experimental results for achieving the power density of 25kW/lit with Inline FIP by keeping lower Peak firing pressure.
Technical Paper

FABRICATION AND WEAR CHARACTERISTICS BASALT FIBER REINFORCED POLYPROPYLENE MATRIX COMPOSITES

2019-11-21
2019-28-2570
Generally brake pads are manufacturing by use of asbestos materials, these materials are chemically harmful and toxic, affects human health. The present investigation fabricates polypropylene composites with mixing constant volume [5 Vol.%] of alumina nano particles and different volume percentages [0%, 5%, 10% & 15%] of basalt fibre by hand layup compression technique. The wear characteristics of polypropylene matrix composites were tested by dry sliding condition using pin on disc apparatus configuration with hardened steel counter-face at elevated temperature. The load was applied 30N to 70N with the interval of 20N and varying of sliding speed 300 rpm to 900rpm with the interval of 300rpm for the time period of 0-180 sec. The wear rate was decreases with addition of alumina nano particle and also increases the frictional force for the effect of basalt fibre content present in the composites. The co-efficient of friction was increases from 0.1 to 0.66 under normal loading condition.
Technical Paper

Development of high power density diesel engine for constant speed application

2019-11-21
2019-28-2566
Engine up gradation for higher power rating involves challenges that require hardware changes which not only increase cost but also demand higher space. This paper focuses on the up gradation of a 4 cylinder 4.9l CRDi engine from 24.03 kW/L to 30.75 kW/L by adjustment of various parameters to meet both emission and performance targets. Various challenges like higher exhaust temperature, increased peak firing pressure etc. were met using the proper calibration strategy. To meet SFC targets and keep peak firing pressures, exhaust temperatures within desired limits, different operating points for EGR, main injection timing, rail pressure have been optimized. The operating points for optimization were determined by conducting various drive trials on different type of load conditions in test bench. Calibration strategy involved the safe limits of NOx, soot, CO emissions, fuel consumption.pfp, and exhaust temperature.
Technical Paper

Combustion Optimization and In-cylinder NOx and PM Reduction by using EGR and Split Injection Technique

2019-11-21
2019-28-2560
Nowadays, the major most challenge in the diesel engine is the oxides of nitrogen (NOx) and particulate matter (PM) trade-off, with minimal reduction in Power and BSFC. Modern day engines also rely on expensive after-treatment devices, which may decrease the performance and increase the BSFC. In this paper, combustion optimization and in-cylinder emission control by introducing the Split injection technique along with EGR is carried out by 1-D (GT-POWER) simulation. Experiments were conducted on a 3.5 kW Single-cylinder naturally aspirated CRDI engine at the different load conditions. The Simulation model incorporates detailed pressure (Burn rate) analysis for different cases and various aspects of ignition delay, premixed and mixing controlled combustion rate, the injection rate affecting oxides of nitrogen and particulate matter.
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